Method for making bodies of compacted powedered material



Oct. 14, 1941. s wELLMAN v 2,259,094

METHOD FOR MAKING BODIES OF COMPACTED POWDERED MATERIAL 5 Shets-Sheet 1 Filed Jan. 9, 1939 W G\ a v 3 m mw m v Fig-'1 INVENTOR A ORIQIEY Oct. 14, 1941. s K, WELLMAN 2,259,094,

METHOD FOR MAKING BODIES OF COMPACTED POWDERED MATERIAL 7 Filed Jan. 9, 1939 s Sheets-She a; 2

Q wA/ Fig-2 V I INVENTOR L M A TORNEY Oct. 14, 1941. s. K. WELLMAN 2,259,094

METHOD FOR MAKING BODIES OF COMPACTED POWDERED MATERIAL Filed Jan. 9, 1959 s Sheets-Sheet s J mgf roR A ORNEY emulsion. 14,1941

1 UNiT-EQ x 4 ZZ 'ATE'NT oFF cs Ms'rnon ros. MAKING scams or con- .mo'rrn rownnann MATERIAL Samuel K. Weliman, Cleveland Heights, Ohio, as-

signor to The S. K. Weilma 11 Company, Cleveland, Ohio, a corporation of Ohio Application January 9, 1939, Serial No. 249,899

- 1 Claim. (Cl. 29-1605) This invention relates a method for makof mixtures of such materials and is especially applicable to the production from metal powders,

' orv mixtures of powdered metal and other Powdered materials, of such articles as antifriction bearing members and friction brake and .clutch linings or facings.

In the production of such bodies of compacted powdered material and especially of matef rials including metals, the body, after being formed, is subjected to a heat treatment to effect sintering for the purpose of securing increased strength and other desirable properties. Prior to such sintering, the bodies of compacted material, while strong enough to permit ordinary 'ing bodies of compacted powdered material or ing their peripheries .confined, has been observedto take the form of bulges, wrinkles, cracks, etc., while in a few instances where the stresses-were more uniformly distributed through the material, the body has been observed to dish outwardly, the center portion moving out of the plane of the edges to form a shallow cone.

Under some conditions, however, the internal stresses set up by this expansion tendency may not be relieved by distortion, due usually to the application of external forces which oppose and handling, are relatively weak and frangible as.

bodies at this stage of manufacture has constituted a very serious dimculty and the primary object of the present invention is to provide a methodby which bodies may be formed of compressed powdered materials and withdrawn from the mold or die without the customary breakage which has usually accompanied such removal.

A further object of my invention is to provide apparatus which is especially suitable for carrying out the above method.

My invention has grown out of the discovery that the objectionable breakage above referred to is due in large measure to the tendency of the bodies of compacted powdered material to expand in size following the removal of the compacting pressure. The amount of such expansion on each dimension is approximately proportional to the magnitude of the dimension. While such expansion is relatively slight and prevent the distortion. However, when these opposing forces are eventually removed, the expansion occurs with the consequent formation f the above mentioned defects. For example, when a plurality: of stacked disc-shaped-compressed bodies areremoved from the compression mold by pushing them out of one end of the mold, the axial pressure needed to so push them out may be suflicient to prevent any dishing, warping, or bulging of the bodies while they are still within the mold, but when a disc has i the cavity of the'mold. The breakage of such been pushed to the open-end so that a portion of it extends outside the mold, that portion which is no longer confined by the walls of the mold will tend to expand, while the balance of the disc is still prevented 'by the mold from such expansion. The result is that the edges of the disc crack, spell, or crumble. This has been the customary defect observed in a large proportion of the compressed bodies which have been removed from the mold in this manner. Furthermore it is a defect which has seriously hindered commercial operations, since breaking or chipof little significance in the case of small dimensions, when dimensions of greater magnitude are involved, the expansion is proportionately greater and may be very considerable. For example, in the case of a facing or a clutch plate or ring compacted in a 12" diameter mold, an. expansion of nearly on the diameter has been observed.

I have found that if the expansion of such bodies is permitted to occur while the body is yet partially confined by the walls of the mold, internal stresses are created which tend to produce distortion of those portions of the body which lie between the confined peripheries. This distortion, in the case of disk shaped bodies havping of the edge ordinarily prevents further use of the article, especially where the mold cavity has been designed to produce a body-which is very close to the size of the element desired in the finished product. For this reason, thedefeet has caused much waste of time, labor, and material, and consequently has created a serious problem which heretofore has not been solved.

Now I have discovered, however, that the expansion in question can be delayed for any length of time after the compressed body has been removed from the mold or from those walls of the mold which directly oppose the expansion. This can be accomplished by applying pressure to the body, and particularly by applying it' to those portions of the faces of the body which lie adjacent the said opposing walls of the mold.

facture by the improved method. Several forms 4 of this apparatus are shown in the accompanying drawings and reference is now made to them since explanation oi. the apparatus at this point will aid in the further explanation of the invention.

In the drawings, Fig. 1 is a vertical section taken through a hydraulic press,'and showing a compression mold. mounted in operative position thereon and holding a charge of the pewdered material to be compressed.

Fig. 2 is a similar cross-section showing the side walls or the mold stripped from around the compressed articles.

Fig. 8 is a fragmentary vertical section show- I compressed against the charge during the stripping operation.

Figs. 4 and 5 are plan and elevation, respectively, or a type oi. multipart mold from which compressed articles may be removed in accordance with the invention disclosed herein, while F18. 6 is an elevation of one of the halves of the mold.

Fig. 7 is a perspective view of a clamp suitable for use with the mold of Figs. 4, 5 and 6.

Fig. .8 is an expanded isometric view of a modification of the mold-shown in Figs. 46, in which the base of the mold is made integral with one 01' the side wall sections.

Since a variety of shapes may be formed with the apparatus shown in the drawings, by providing an appropriately shaped mold, it will be understood that the specific molds shown in the drawings are used merely for purposes of illustration.

In the figures, in which like parts bear like numerals, l is the press main-frame joining the stationary .pre'ss head 2 with base 3. Base 3 supports stationary piston 4 on which is guided main hydraulic cylinder 5. On the surface of cylinder 5 rests stripping head designated generally by the numeral 8 which is suitably centered thereon, and secured by appropriate means well known to those skilled in the art. Positioned within the stripping head 8 are a plurality of pistons I and 8, 8 capable of being raised by bydraulic pressure, or otherwise, in the corresponding cylinders 9 and III, III, respectively, each being surrounded by a compression spring 33.

On the stripping head is disposed a forming mold or die comprising outer ring ll, core member l3 and bottom and top compression rings l6, I6, said mold having an annular chamber or cavity I 2 between the parts II and i3. The mold parts are so positioned on the surface of stripping head 6 that the outermost pistons 8, 8 may, when raised, contact the outer mold ring II without entering chamber l2: and so that central piston 1 may, when raised, contact core member secured to press head 2, as through bar 30, screws 3| and 3 2, and is so shaped as to enter the mold cavity l2 when main cylinder 5 is raised toward press head 2.

Chamber I2 is partially filled with powdered metal mixture ll distributed alternately between spacer rings IS, the whole pile being closed top and bottom with the heavy compression rings [6' and It. It will be obvious, of course, that a plurality of such layers of powder may be included, or a single layer alone.- The number which may be so formed depends on the travel of the press, the thickness of the individual layers making up depth of the mold, and the frictional characteristics of the powder against the mold walls.

Hydraulic fluid under pressure is admitted from any suitable pump or pressure reservoir through conduit A to main valve B and then through conduit l8 into chamber l9 which is formed between piston 4 and cylinder 5. An opening 20 in cyl-,

inder 5 permits hydraulic fluid to flow i'rom chamber I! through conduit 2| as far as valve 22 when the latter is closed. When it is opened the fluid may then pass through conduit 23 into chambers 24 beneath pistons I and 8, 8, where it may act thereon to force each of them upwardly toward press head 2.

It will, of course, be apparent that instead of supplying hydraulic fluid to valve 22 from chamber l9, it may equally well be supplied directly from main conduit A or iro'm. a separate pump or reservoir. In either of these constructions, however, flexible high pressure connections must be used in order to accommodate the vertical movement of cylinder 5 with its attached strippinghead 6. The arrangement shown in Figs.

1 and 2 therefore has the advantage that such connections are avoided.

Pistons 4, 1 and 8, 8 are each provided with the usual gaskets 25 and 250, respectively, which seal the piston and cylinder assemblies against leakage of the. hydraulic fluid. The gaskets are suitably reinforced by retainer plates 26 and 26a which are in turn secured to the pistons.

Mold members II and I3 and ram I'I are provided with small holes 21, 28 and 29, respectively, the purpose of which will appear in a later part of the description.

Having now described one form of apparatus which may be used, its operation will be explained in terms of a specific application. The method of operation and'the apparatus are applicable to a wide variety of shapes and compositions, but the production of friction clutch rings will serve to illustrate the operations involved.

In preparing the press for operation, an appropriate stripping head is mounted on the main l! cylinder, the stripping head being chosen so that its pistons I and 8, 8 are properly spaced to lit the mold members I I and 13 which are to be used. proper stationary ram I1 is fitted to the press ead. Cylinder 5 and pistons I and 8, 8 are 59' then lowered by opening valves B and 22, respec- Work plate with bottom compression ring I6 spacing them apart, and are rotated relative to each other until hole 21 and 29 are brought into axial alignment on a line radial to the mold cavity. A charge of suitable mixed powder is I! A stationary compression ram I I is rigidly :60 then Weighed out. such a charge may be composed, ior example, of the following ingredients:

The charge is poured into chamber l2 and there thoroughly distributed upon the surface of ring l6 so as to form a thin layer of uniform thickness. A spacer ring l5, conforming. precisely to the shape and dimensions of cavity I 2, and having been ground so as to have plane parallel the pile, the compressibility of the powder. the surfaces and uniform thickness throughout.- is

/ then admitted into, chamber [2 and gently eased .intoposition on top of the powder layer. A secnd weighed charge is then added, and distrib:

uted, and theabove' procedure repeated. After a suitable number of charges have been-:adde'd, the top compression ring IGKisinsertedontop of the. last-powder layer. :The charges are then ready tobe compacted in the press The charged mold assembly is now transported to the-press andispositioned on'thesurface of stripping head 6, its position .thereon 'being adjusted so that cavity. i2 is inalignment with ram then opened wide to subject-the charge to full compression pressure. For the above composition, suitable full pressure has been found to be about 22,090 pounds per square inch. -It will be appreciated, of course, that this value is merely illustrative, since with any given composition, the pressure may be varied widely depending on the properties which are desired in the sintered article. After this predetermined pressure has been attained, and the layers of powder have been compacted the desired amount,v valve 22 is cracked to allow hydraulic fluid to escape into cylinders 9 and I0, Ill; The valve is manipulated in such manner that the pressure exerted on the charge bythe main cylinder is maintatined not much below the desired compression pressure,

,1. e., 22,000 pounds per square inch. The fluid permitted to escape from chamber i9 through valve 22 gradually accumulates in cylinders 9 and I0 and forces pistons I and 8, 8 upwardly against the bases of mold members II and I3, respectively. As the pressure under these cylinders gradually increases, mold members II and I3 are forced upwardly and away from the charge l4, l4 until the full charge is exposed to view. It should be particularly noted at this point that with proper manipulation of valve B and 22 the charge will have been held under full compression pressure even though fluid has been withdrawn from beneath the main cylinder and passed into the stripping head. When the mold members I I and I3 have reached such a height above the charge that holes 21, 28 and 29 are in axial alignment, 9. pin 34 is inserted through them. This condition is shown in Fig. 2. The main hydraulic pump is now stopped and with valve B open, the fluid in chambers i9 and 24 is permitted to be forced out by the springs 33 surrounding pistons 1 and 8, 8 and by the weight carried by cylinder 5, until these parts are again in their normal positions. Mold members II and I3 remain suspended around ram from pin 34, while the charge in cavity -I3 remains on the surface of stripping head 6 and islowered away from- The charge is now free of pressure and may be removed from the press. The compressed bodies are separated from separator rings l5 and after being brushed free from any adhering loose powder, are ready to be-sintered or otherwise treated.

Returning again to the press, cylinder 5 is now raised until stripping head 6 again contacts die sembly in preparation for another charge.

In the, above described-procedure, ,while the mold side walls ii and I3 are being stripped from the charge the-compressed .bodies H are main- 10 tained undersumciently high pressure atright angles totheir faces and preferably out'totheir' outer peripheries; to insure that the internalexpansive stresses in" the compressed'bodies are, counteracted sufilciently by the frictional forces. thus established to prevent expansionof saidbodies when they are moved out of engagement with the restraining mold walls. In other words,

no expansion of the compressed bodies. is permitted until they have been. entirely removed from contact with the restraining side walls of the mold and, consequently, when the pressure upon the faces of the compressed bodies is laterremoved and radialexpansion of said bodies is permitted, there is nothing to restrain such expan- 5 sion in any part of the compressed body so that there is no tendency to fracture-the edge parts thereof in the manner which has characterized the prior methods of manufacture. The intensity of the pressure needed to secure this result in any particular case will depend upon the var ious factors indicated in the foregoing description. The remarkable restraining effect of the.

pressure to which the faces of the disk-shaped bodies are subjected is visually demonstrated in a striking manner in the procedure which has been described, for as the said pressure is released-the compressed disks may be seen to expand radially beyond. rings l5 and 16. Furthermore, by the simple expedient of holding the compressed bodies under pressure after the side walls of the 5 may take a variety of forms since its pistons must necessarily be placed in conformity with the molds or dies which are to be used on it. Fur-. thermore, it is not necessary that hydraulic pressure be used to strip the molds. For example, one

form of stripping head which may be used is shown in Fig. 3, in which the pressure applied on the compressed bodies is obtained by compressing the rubber pad 35, while the mold members are pushed upwardly by fingers 36. The

5 operation of this device is obvious; After the charge 31 has been compressed, but before main cylinder 5 has been lowered, hooks 38 areattached to the mold assembly and screws 39 inserted into-ring Ilia from mold member 40. The

main cylinder is then lowered, and the stripping head 45 placed thereon. The cylinder is now again raised, and enough rubber pads inserted under the charge that appreciable compression of them will occur before fingers 36 contact mold 5 member 40. The cylinder is now raised until fingers 36 touch and support mold 40. Screws 39- are removed, and hooks 38 loosened. Now on raising the cylinder further, mold 40 is forced upward and stripped from around the charge,

while rubber pads 35 compress more and more against the charge. To complete the operation,

. mold 40 is now hooked inits uppermost position, the cylinder lowered to relieve the pressure on the charge, and the charge removed.

While this type of stripping device accomplishes v 2 members II. and i3 and supports them. The pin 34 which waspassed through holes- 21, 28. and 29 is now withdrawnand cylinder 5 lowered,, whereupon mold members II and. l3become ,sep- 5. arated from ramit and are again ready for asthe desired results, its use requires many press operations which consume much time. The hydraulic stripper, on the other hand, is easier to use and is much faster. JBecause of these advantages the hydraulic device is to be preferred for commercial operations.

In connection with the use of rubber pads for stripping, it is to be noted that while the compressed charge is hooked up against the ram, and before the stripper has been raised to exert pressure on the charge, the charge may be under very little pressure. Even so, however, no damage to the compressed bodies occurs during stripping since pressure is again applied to them before the mold wall is stripped off.

In connection with stripping it is to be pointed out further that the pressure which need be exerted against the charge-during stripping is small. Indeed, it need only be the value obtained by multiplying the value of internal stress in the compressed body by the coeflicientof friction between the body and the material .of the separator. Obviously, if a separator material is used which has a low coefilcient of friction with the body, the pressure needed to prevent expansion may be relatively large, while if the separator material against the compressed body has a large coefliceint of friction, the pressure will be proportionately small. In practice, using high carbon steel separators with the powder composition given above, pressure as low as 1000 pounds per square inch can be used.

The method of this invention may also be practiced without using any sort of stripping head, as for instance, with multipart or sectional molds such as are represented by the mold asse mbly shown in Figs. 4, 5, 6 and 8. Figures 4, 5 and 6 show a sectional mold wall comprising a plurality of sections 4| and 42 adapted to fit together to form the desired shape of compression cavity. Each section carries a number of lugs 43 so positioned as to cooperate with similar lugs on adjacent sections, whereby a clamp 44 may be tightly fitted therearound to hold the sections together. Such a mold assembly may have the bottom separate from the sides as at 46 in Figs. 4 and 5, or integral with one side wall as in the modified construction shown in Fig. 8, where the mold comprises sections Ila and 42a with clamp lugs 43a, and section 42a is formed with a bottom wall section 46a.

When using this type of mold shown in Figs. 4 to 8, the ram is forced into the open upper end of the mold cavity to compress the charge. After the charge has been compressed, the compression pressure may be held at its maximum value or reduced to that pressure which will just prevent expansion, or to any intermediate value. The clamps 44 may then be knocked off of the lugs 43 or 43a, and one of the mold sections, such as 4| or Ma, removed or stripped away. The pressure may then be fully released and the compressed bodies removed. Obviously, when the mold sections are of irregular shape, the portion or portions of the mold which must be removed as described will be such as to permit the compressed body to expand freely when the pressure is released.

It will be understood that the various modifications described above have been chosen merely to illustrate the invention, and should not be regarded in a limiting sense since other modifications are possible within the bounds of the following claim, which indicates the scope of the invention.

What I claim is:

The method of making. a thin -flat briquette composed of powdered materials which are predominantly metallic and which, when compressed to form the briquette, impart to the briquette a tendency to expand along its major dimensions when the compacting pressure under which it is formed is released, said method comprising the steps of: providing a mold having a continuous and uniointed peripheral cavity wall and two mutually opposite walls both of which are disposed transversely to the peripheral cavity wall and one of which is movable toward the other to exert pressureon powdered metallic material surrounded by the peripheral wall; charging the aforesaid powdered material into the mold cavity to form therein a layer which may be compressed to the desired thickness between said opposite walls; moving one of the opposite mold walls toward the other and pressing with a pressure of more than a 1000 lbs. per square inch the powdered material within the mold to press the latter against the peripheral cavity wall and to compact and form it into a coherent briquette; continuously clamping at least the peripheral portions of the briquette between the said opposite walls of the mold under a positive pressure sufllciently great to prevent substantial expansion of the peripheral boundary of the briquette when the said peripheral cavity wall has been removed from restraining contact with the periphery of the briquette, said clamping pressure being not less than about 1,000 pounds per square inch and not more than the compacting pressure used in forming the briquette; effecting removal of the said unjointed peripheral cavity wall from all restraining contact with the periphery of the briquette while the latter is continuously clamped as aforesaid, by displacing the peripheral cavity wall parallel to the thickness of the briquette; and thereafter releasing said briquette from said clamping pressure to allow it to expand.

SAMUEL K. WELLMAN. 

